JP2002320896A - Paint supply head and method of manufacturing decorative plate - Google Patents
Paint supply head and method of manufacturing decorative plateInfo
- Publication number
- JP2002320896A JP2002320896A JP2001127573A JP2001127573A JP2002320896A JP 2002320896 A JP2002320896 A JP 2002320896A JP 2001127573 A JP2001127573 A JP 2001127573A JP 2001127573 A JP2001127573 A JP 2001127573A JP 2002320896 A JP2002320896 A JP 2002320896A
- Authority
- JP
- Japan
- Prior art keywords
- paint
- supply head
- slit
- opening
- mixing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000003973 paint Substances 0.000 title claims abstract description 276
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- 238000000576 coating method Methods 0.000 claims abstract description 71
- 239000011248 coating agent Substances 0.000 claims abstract description 67
- 238000000034 method Methods 0.000 claims abstract description 35
- 238000002156 mixing Methods 0.000 claims abstract description 28
- 239000000758 substrate Substances 0.000 claims description 55
- 229920005989 resin Polymers 0.000 claims description 26
- 239000011347 resin Substances 0.000 claims description 26
- 239000007788 liquid Substances 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 15
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 230000002093 peripheral effect Effects 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 106
- 239000000919 ceramic Substances 0.000 description 36
- 230000002940 repellent Effects 0.000 description 27
- 239000005871 repellent Substances 0.000 description 27
- 239000000049 pigment Substances 0.000 description 20
- 239000003795 chemical substances by application Substances 0.000 description 17
- 230000001846 repelling effect Effects 0.000 description 17
- 239000002585 base Substances 0.000 description 16
- 238000001723 curing Methods 0.000 description 13
- 238000013461 design Methods 0.000 description 13
- 230000000694 effects Effects 0.000 description 12
- 229920002545 silicone oil Polymers 0.000 description 12
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 9
- 239000004566 building material Substances 0.000 description 5
- 230000007547 defect Effects 0.000 description 5
- 238000011156 evaluation Methods 0.000 description 5
- 229920001187 thermosetting polymer Polymers 0.000 description 5
- 238000011282 treatment Methods 0.000 description 5
- 239000004925 Acrylic resin Substances 0.000 description 4
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000005498 polishing Methods 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 238000003756 stirring Methods 0.000 description 4
- 238000012546 transfer Methods 0.000 description 4
- 238000011144 upstream manufacturing Methods 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 3
- 229920000178 Acrylic resin Polymers 0.000 description 3
- 239000004568 cement Substances 0.000 description 3
- NCEXYHBECQHGNR-UHFFFAOYSA-N chembl421 Chemical compound C1=C(O)C(C(=O)O)=CC(N=NC=2C=CC(=CC=2)S(=O)(=O)NC=2N=CC=CC=2)=C1 NCEXYHBECQHGNR-UHFFFAOYSA-N 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 230000002950 deficient Effects 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000010422 painting Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920005749 polyurethane resin Polymers 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000002834 transmittance Methods 0.000 description 3
- 229920006337 unsaturated polyester resin Polymers 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052918 calcium silicate Inorganic materials 0.000 description 2
- 239000000378 calcium silicate Substances 0.000 description 2
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 2
- 239000011247 coating layer Substances 0.000 description 2
- 238000004040 coloring Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000007865 diluting Methods 0.000 description 2
- 238000010894 electron beam technology Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000003999 initiator Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- 101001024616 Homo sapiens Neuroblastoma breakpoint family member 9 Proteins 0.000 description 1
- 102100037013 Neuroblastoma breakpoint family member 9 Human genes 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 102100025490 Slit homolog 1 protein Human genes 0.000 description 1
- 101710123186 Slit homolog 1 protein Proteins 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- QHIWVLPBUQWDMQ-UHFFFAOYSA-N butyl prop-2-enoate;methyl 2-methylprop-2-enoate;prop-2-enoic acid Chemical compound OC(=O)C=C.COC(=O)C(C)=C.CCCCOC(=O)C=C QHIWVLPBUQWDMQ-UHFFFAOYSA-N 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 239000004035 construction material Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 239000011087 paperboard Substances 0.000 description 1
- 239000011049 pearl Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000003504 photosensitizing agent Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000009751 slip forming Methods 0.000 description 1
- 239000002345 surface coating layer Substances 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Landscapes
- Application Of Or Painting With Fluid Materials (AREA)
- Coating Apparatus (AREA)
- Laminated Bodies (AREA)
Abstract
(57)【要約】
【課題】 混合分散または混合溶解しにくい成分を含む
塗料であっても、安定した塗料カーテンを連続的に形成
して均一に塗装することができる塗料供給ヘッド及びそ
れを用いた化粧板の製造方法を提供する。
【解決手段】 長箱状の容器11の底部に形成された塗
料流下用のスリット12とスリット12の上部に連結さ
れた斜面部13とから塗料溜まり部14が画成され、ス
リット12の上方で且つスリット12と平行に配設され
た供給管15の両端がそれぞれ導入管に連結されてい
る。供給管15には下向きに開口された複数の供給孔が
形成され、供給管15を収容すると共にスリット12と
平行に配設された塗料混合分散用の樋19に上向きの開
口部20が形成されている。
PROBLEM TO BE SOLVED: To provide a paint supply head capable of continuously forming a stable paint curtain and uniformly coating even a paint containing a component which is hardly mixed-dispersed or mixed-dissolved, and using the same. Provided is a method for manufacturing a decorative panel. SOLUTION: A paint pool portion 14 is defined by a paint flow-down slit 12 formed at the bottom of a long box-shaped container 11 and a slope portion 13 connected to the upper portion of the slit 12, and a paint pool portion 14 is formed above the slit 12. Further, both ends of the supply pipe 15 arranged in parallel with the slit 12 are connected to the introduction pipe. A plurality of supply holes opened downward are formed in the supply pipe 15, and an upward opening 20 is formed in a paint mixing / dispersing gutter 19 provided in parallel with the slit 12 to accommodate the supply pipe 15. ing.
Description
【0001】[0001]
【発明の属する技術分野】この発明は、板状の建築材料
等の被塗装物に塗装する塗装装置に関し、特にスリット
により塗料カーテンを形成して塗装を行うフローコータ
ーの塗料供給ヘッドに関する。また、この発明は、意匠
性、特に光揮感、立体感、陰影感、深み感に優れた化粧
板の製造方法、特にバスユニット内壁、トイレブース、
キッチン前面板等の内装材に利用可能な化粧板の製造方
法にも関している。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coating apparatus for coating an object to be coated such as a plate-shaped building material, and more particularly to a coating supply head of a flow coater for coating by forming a coating curtain with slits. In addition, the present invention provides a method for producing a decorative board excellent in design properties, in particular, light feeling, three-dimensional feeling, shading, and depth, particularly, a bath unit inner wall, a toilet booth,
The present invention also relates to a method for manufacturing a decorative board that can be used as an interior material such as a kitchen front panel.
【0002】[0002]
【従来の技術】一般的なフローコーターによる塗装と
は、塗布しようとする液体塗料をスリットに通すことに
より液体塗料の粘性を利用して一定幅の薄いカーテン状
またはフィルム状の塗料カーテンを上方から連続的に供
給、形成し、被塗装物に塗装を行う方法である。具体的
には、タンクに貯留された塗料を塗料ポンプにより塗料
供給ヘッドに供給し、この塗料供給ヘッドに形成された
スリットにより一定幅の薄いカーテン状またはフィルム
状の塗料カーテンを上方から連続的に供給、形成する一
方、コンベアにより被塗装物を移動させて塗料カーテン
の下部を潜行させることにより塗装が行われる。被塗装
物に付着されなかった塗料は塗料回収桶により回収され
てタンクに送られ、再び塗料ポンプにより自動的に循環
される。2. Description of the Related Art A coating by a general flow coater means that a liquid paint to be applied is passed through a slit so as to utilize a viscosity of the liquid paint to form a thin curtain-shaped or film-shaped paint curtain having a fixed width from above. This is a method of continuously supplying and forming, and coating an object to be coated. Specifically, the paint stored in the tank is supplied to a paint supply head by a paint pump, and a thin curtain or film-like paint curtain having a fixed width is continuously formed from above by a slit formed in the paint supply head. While being supplied and formed, painting is performed by moving an object to be painted by a conveyor so as to move under the paint curtain. The paint that has not adhered to the object to be coated is collected by a paint collection tub, sent to a tank, and automatically circulated again by a paint pump.
【0003】このようなフローコーターの式の塗料供給
ヘッドに関して、安定した塗料カーテンを形成して均一
な塗装を行うために各種の提案がなされている。例え
ば、実公平2−3829号公報には、塗料供給ヘッドの
一端からその内部に塗料を吐出させると共に、塗料供給
ヘッド内に吐出側を疎とし且つその反対側が密となるよ
うな間隔の複数の孔を形成したフィルターを設け、塗料
供給ヘッドに形成されたスリットによりカーテン状に塗
料を流下させる装置が開示されている。また、特開平1
0−323603号公報には、塗料供給ヘッド内の流下
経路に相対する流路壁から流路内へ交互に突出したブレ
ードが設けられたカーテンヘッドが開示されている。さ
らに、特開平11−128803号公報には、塗料供給
ヘッド内に流下スリットに連接されたテーパ面に断面V
字状の樋を設け、この樋の底部角部にスリットを形成し
たものが開示されている。Various proposals have been made for such a flow coater type paint supply head in order to form a stable paint curtain and perform uniform coating. For example, Japanese Utility Model Publication No. 2-3829 discloses that a paint is discharged from one end of a paint supply head into the paint supply head and a plurality of paints are spaced inside the paint supply head so that the discharge side is sparse and the opposite side is dense. There is disclosed an apparatus in which a filter having holes is provided and paint is caused to flow down in a curtain shape by a slit formed in a paint supply head. Also, Japanese Patent Application Laid-Open
Japanese Patent Application Publication No. 0-323603 discloses a curtain head provided with blades that alternately protrude into a flow path from a flow path wall facing a flow-down path in a paint supply head. Further, Japanese Patent Application Laid-Open No. 11-128803 describes that a tapered surface connected to a flowing down slit has a cross section V in a paint supply head.
A gutter having a U-shaped gutter and a slit formed at the bottom corner of the gutter is disclosed.
【0004】一方、塗装により高い意匠性を付与する目
的で、塗料中に分散しにくい顔料や塗料に対して溶解し
にくい液状の添加剤や界面活性剤などを添加または混合
した塗料が用いられるようになってきた。例えば、特開
平10−291274号公報には、意匠性、特に光輝
感、立体感、陰影感、深み感を高めた化粧建材の製造方
法が開示されている。この化粧建材は平滑な基材表面に
化粧層を設け、その上にシリコーンオイルが分散した表
面塗膜層を設けた化粧建材であり、該化粧建材の製造方
法は、図柄印刷された化粧紙や熱転写樹脂シートを化粧
層とし、その上にシリコンオイルが分散混合した塗料を
ロールコーターまたは従来の塗料供給ヘッドを使用した
フローコーターを用いて塗装し、シリコンオイルのはじ
き効果を利用して塗膜表面に凹凸を付け深み感をもたせ
ようとするものである。また前記塗料には顔料としてア
ルミニウム粉が導入可能であるとされている。On the other hand, for the purpose of imparting a high design property by coating, a paint to which a pigment which is hardly dispersed in the paint, a liquid additive which is hardly soluble in the paint, a surfactant or the like is added or mixed is used. It has become For example, Japanese Patent Application Laid-Open No. Hei 10-291274 discloses a method of manufacturing a decorative building material with improved design properties, in particular, brilliant, three-dimensional, shading, and deep feeling. This decorative building material is a decorative building material in which a decorative layer is provided on a smooth base material surface, and a surface coating layer in which silicone oil is dispersed is provided thereon. A thermal transfer resin sheet is used as a decorative layer, and a coating in which silicone oil is dispersed and mixed is applied using a roll coater or a flow coater using a conventional coating supply head, and the coating surface is applied using the repelling effect of silicone oil. It is intended to give a sense of depth by making the surface uneven. It is also stated that aluminum powder can be introduced as a pigment into the paint.
【0005】[0005]
【発明が解決しようとする課題】しかしながら、シリコ
ンオイルが分散混合された塗料を従来の塗料供給ヘッド
を用いたフローコーターで基材上に塗布する場合におい
ては、シリコンオイルと前記塗料との組成、性状(相溶
性、表面張力等)の相違により、塗料供給ヘッド最下部
に位置する塗料流下スリット部にて形成される塗料カー
テンが切れる、あるいは破れる「カーテン切れ」を来す
ため、通常市販されている構造の従来の塗料供給ヘッド
を用いたフローコーターでの塗装が不可能、あるいは
「カーテン切れ」に起因する塗膜欠陥(塗装不良)が多
発し安定した塗装(製造)ができないという問題点があ
った。However, when a paint in which silicone oil is dispersed and mixed is applied to a substrate by a flow coater using a conventional paint supply head, the composition of the silicone oil and the paint, Due to differences in properties (compatibility, surface tension, etc.), the paint curtain formed at the paint flow slit located at the lowermost part of the paint supply head is cut or broken. Coating with a flow coater using a conventional paint supply head with a conventional structure is impossible, or coating defects (defective coating) due to "cut curtain" occur frequently and stable coating (manufacturing) cannot be performed. there were.
【0006】また、化粧建材の意匠性を高めるために、
シリコンオイルの添加量を多くするにつれて「カーテン
切れ」の発生回数が増す傾向を示すため、目的とする意
匠性を得ようとすると、塗装不良の増大を招くという問
題点もあった。更には、シリコンオイルが分散混合され
た塗料が「カーテン切れ」を生じることなく塗装できた
としても、塗料カーテンが不安定となり、前記塗料への
シリコンオイルの分散混合状態が必ずしも均一とならな
いため、付与された模様の大きさが不均一で、特に基材
の中央部と端部で模様の大きさが異なり、柄の再現性の
ある製品の製造ができないという問題点もあった。In order to enhance the design of decorative building materials,
Since the number of occurrences of "curtain breakage" tends to increase as the amount of silicon oil added increases, there is also a problem in that an attempt to obtain a desired design property causes an increase in defective coating. Furthermore, even if the paint in which the silicone oil is dispersed and mixed can be applied without causing `` curtain breaks '', the paint curtain becomes unstable, and the dispersed and mixed state of the silicone oil in the paint is not necessarily uniform, There is also a problem that the size of the applied pattern is not uniform, and the size of the pattern is particularly different between the central portion and the end portion of the base material, so that it is impossible to manufacture a product with a reproducible pattern.
【0007】さらに、特開平11−128803号公報
に開示されている装置は、塗料供給ヘッド内部に底部角
部にスリットを施した断面V字状の樋を塗料供給ヘッド
最下部に位置する塗料流下スリットに連結したテーパ面
に取り付けることを特徴としており、粘度が低く、粗骨
材を含む塗料であっても安定した塗料カーテンを形成し
て均一塗装を行うことが可能であるとされている。該装
置は粘度が低く、粗骨材を含む塗料には有効であるかも
知れないが、意匠性を高める目的等で塗料中に、例えば
シリコーンオイルの様な塗料の組成・性状とは異なる添
加剤を混合した塗料を従来の塗料供給ヘッドを用いたフ
ローコーターで塗装する場合においては、導入管より塗
料供給ヘッド内に吐出した塗料が、断面V字状樋へ落下
する際に空気を巻き込み、これにより塗料カーテンが不
安定となり「カーテン切れ」を来し、また、「カーテン
切れ」を生じないまでも得られる塗料カーテンが不安定
となり、柄に再現性のある製品の製造が出来ない。Further, in the apparatus disclosed in Japanese Patent Application Laid-Open No. 11-128803, a gutter having a V-shaped cross section with a slit at the bottom corner is provided inside the paint supply head at the bottom of the paint supply head. It is characterized in that it is attached to a tapered surface connected to a slit, and it is said that a uniform coating can be performed by forming a stable coating curtain even with a coating material having a low viscosity and a coarse aggregate. This device has a low viscosity and may be effective for paints containing coarse aggregates, but additives for the purpose of enhancing the design, etc., which are different from the paint composition and properties, such as silicone oil, are added. When the paint mixed with the above is applied by a flow coater using a conventional paint supply head, when the paint discharged from the introduction pipe into the paint supply head falls into the V-shaped gutter in the cross section, air is entrapped, and As a result, the paint curtain becomes unstable, leading to "cut curtain", and even if the "curtain break" does not occur, the obtained paint curtain becomes unstable, making it impossible to produce a product with a reproducible pattern.
【0008】そこで、この発明は上記問題点を解消する
ためになされたもので、分散しにくい顔料や塗料に対し
て溶解しにくい液状の添加剤や界面活性剤などを添加ま
たは混合した塗料を用いても、安定した塗料カーテンを
連続的に形成して意匠性の高い、塗膜の物性に優れた塗
装を行うことができるフローコーターの塗料供給ヘッド
を提供することを目的とする。Accordingly, the present invention has been made to solve the above problems, and uses a paint to which a liquid additive or a surfactant which is hardly dissolved in a pigment or a paint which is difficult to disperse is added or mixed. In particular, it is an object of the present invention to provide a paint supply head of a flow coater capable of continuously forming a stable paint curtain and performing coating with high design properties and excellent physical properties of a coating film.
【0009】また、この発明は、特にはじき剤を添加し
た塗料をフローコーターで塗装する際に「カーテン切
れ」等の塗装不良を来すことなく、模様と柄の再現性の
ある製品の安定的な製造が可能であり、しかも意匠性、
特に光揮感、立体感、陰影感、深み感に優れた化粧板の
製造方法を提供することにある。なお、本明細書中に記
載している柄とは、化粧層形成用塗料に添加するはじき
剤の作用により形成される意匠をいい、模様とは、巨視
的な窯業系化粧板としての意匠をそれぞれいう。Further, the present invention provides a method for stably producing a product having reproducibility of a pattern and a pattern without causing a coating defect such as "cut curtain" when coating a coating material to which a repellent is added by a flow coater. Production is possible, and the design,
In particular, it is an object of the present invention to provide a method for producing a decorative board excellent in light feeling, three-dimensional feeling, shading, and depth. In addition, the pattern described in this specification refers to a design formed by the action of a repellent added to a paint for forming a decorative layer, and the pattern refers to a design as a macroscopic ceramic decorative panel. Say each.
【0010】[0010]
【課題を解決するための手段】この発明に係るフローコ
ーターの塗料供給ヘッドは、底部に形成された塗料流下
用のスリットとこのスリットの上部に連結された斜面部
とにより塗料溜まり部が画成された長箱状の容器と、容
器の内部に塗料を導入するための導入管と、容器内に配
設されると共に導入管に連結され且つ導入管により導入
された塗料を容器内に供給するための開口部を有する供
給手段と、供給手段から供給された塗料を一旦受け入れ
ると共にその塗料を容器の塗料溜まり部に供給するため
の開口部を有する混合分散手段とを備えたものである。According to the present invention, there is provided a paint supply head for a flow coater, wherein a paint pool is defined by a paint flow-down slit formed at a bottom portion and a slope portion connected to an upper portion of the slit. A long box-shaped container, an introduction pipe for introducing paint into the interior of the container, and provided in the vessel, connected to the introduction pipe, and supplying the paint introduced by the introduction pipe into the container. And a mixing and dispersing means having an opening for temporarily receiving the paint supplied from the supply means and supplying the paint to the paint reservoir of the container.
【0011】なお、供給手段の開口部の開口方向を下向
きに、混合分散手段の開口部の開口方向を上向きにする
ことができ、この場合、供給手段の開口部の最上位置が
混合分散手段の開口部の最下位置より下に位置するよう
に構成することが好ましい。また、混合分散手段はスリ
ットと略平行に配設された樋から構成することができ、
樋の断面形状をU字状、V字状、コ字状又はL字状とす
ることができる。一方、供給手段はスリットと略平行に
配設され且つ外周部に開口部が形成された管から構成す
ることができ、開口部としては、管の長さ方向に沿って
形成された複数の孔、あるいは管の長さ方向に沿って形
成された細長い線形スリットが用いられる。複数の孔を
用いる場合には、管内の塗料の流れ方向に対して上流側
が疎に、下流側が密になるような間隔で形成することが
好ましい。また、線形スリットを用いる場合は、管内の
塗料の流れ方向に対してスリット幅が上流側で狭く、下
流側で広くなるように形成することが好ましい。The opening direction of the opening of the supply means can be directed downward, and the opening direction of the opening of the mixing and dispersing means can be directed upward. It is preferable to configure so as to be located below the lowermost position of the opening. Further, the mixing and dispersing means can be constituted by a gutter disposed substantially parallel to the slit,
The cross section of the gutter can be U-shaped, V-shaped, U-shaped or L-shaped. On the other hand, the supply means can be constituted by a tube which is disposed substantially parallel to the slit and has an opening formed in the outer peripheral portion, and the opening includes a plurality of holes formed along the longitudinal direction of the tube. Alternatively, an elongated linear slit formed along the length of the tube is used. When a plurality of holes are used, the holes are preferably formed at intervals such that the upstream side is sparse and the downstream side is dense with respect to the flow direction of the paint in the pipe. When a linear slit is used, it is preferable that the slit width is narrower on the upstream side and wider on the downstream side in the flow direction of the paint in the pipe.
【0012】また、この発明に係る化粧板の製造方法
は、基板の表面に上記本発明の塗料供給ヘッドを用いた
フローコーターで塗料を塗布し、硬化させて化粧層を形
成する方法である。好ましくは、基板が、金属板、無機
質板、木質板、紙板、樹脂板及びフィルム(薄板)のいず
れかであり、基板にあらかじめ下地調整層を設けること
もできる。さらに、透明または半透明のトップクリア層
を化粧層上に形成してもよい。なお、塗料供給ヘッド内
における塗料の液面は、混合分散手段の開口部から混合
分散手段の最下部までの範囲に維持することが望まし
い。Further, a method of manufacturing a decorative board according to the present invention is a method of applying a paint to a surface of a substrate with a flow coater using the paint supply head of the present invention and curing the paint to form a decorative layer. Preferably, the substrate is any one of a metal plate, an inorganic plate, a wooden plate, a paper plate, a resin plate, and a film (thin plate), and the substrate may be provided with a base adjustment layer in advance. Further, a transparent or translucent top clear layer may be formed on the decorative layer. It is desirable that the liquid level of the paint in the paint supply head is maintained in a range from the opening of the mixing and dispersing means to the lowermost part of the mixing and dispersing means.
【0013】[0013]
【発明の実施の形態】以下、この発明の実施の形態を添
付図面に基づいて説明する。 実施の形態1. (塗料供給ヘッド)図7にフローコーター式塗装装置の
全体構成を示す。混合撹拌装置付きのタンク1に貯留さ
れた塗料2をポンプ3により導入管4を経由して塗料供
給ヘッド5に定量供給し、この塗料供給ヘッド5に形成
されたスリット6に塗料2を通すことにより一定幅の薄
いカーテン状またはフィルム状の塗料カーテン7を上方
から連続的に供給、形成し、コンベア8及び9により被
塗装物Aを移動させて塗料カーテン7の下部を潜行させ
ることによって被塗装物Aの表面に塗料を付着させる。
被塗装物Aに付着されなかった塗料2は塗料回収桶(塗
料受け)10により回収されてタンク1へ送られ、再び
ポンプ3により自動的に循環される。Embodiments of the present invention will be described below with reference to the accompanying drawings. Embodiment 1 FIG. (Paint Supply Head) FIG. 7 shows the overall configuration of a flow coater type coating apparatus. The paint 2 stored in the tank 1 equipped with the mixing and stirring device is quantitatively supplied to the paint supply head 5 via the introduction pipe 4 by the pump 3, and the paint 2 is passed through the slit 6 formed in the paint supply head 5. , A thin curtain-shaped or film-shaped paint curtain 7 having a constant width is continuously supplied and formed from above, and the workpiece A is moved by the conveyors 8 and 9 so that the lower part of the paint curtain 7 is sunk. A paint is attached to the surface of the object A.
The paint 2 that has not adhered to the work A is collected by a paint collection tub (paint receiver) 10 and sent to the tank 1, and is again automatically circulated by the pump 3.
【0014】この実施の形態1に係る塗料供給ヘッドを
図1及び図2に示す。塗料供給ヘッドは長箱状の容器1
1を有し、この容器11の底部に塗料流下用のスリット
12が形成されると共にスリット12の上部に連結され
て斜面部13が形成されている。これらスリット12と
斜面部13とにより容器11内に塗料溜まり部14が画
成されている。容器11内には、スリット12の上方で
且つスリット12と平行に供給管15(供給手段)が配
設され、供給管15の両端がそれぞれ容器11の左右の
外側面に取り付けられている導入管16及び17に連結
されている。供給管15には下向きに開口された複数の
供給孔18が形成されている。この供給管15を収容す
るようにスリット12と平行に塗料混合分散用の樋19
(混合分散手段)が配設されている。図3に示されるよ
うに、樋19はコ字状の断面形状を有し、上向きの開口
部20を有している。FIG. 1 and FIG. 2 show a paint supply head according to the first embodiment. The paint supply head is a long box-shaped container 1
A slit 12 for flowing paint is formed at the bottom of the container 11 and a slope 13 is formed by being connected to the upper part of the slit 12. A paint reservoir 14 is defined in the container 11 by the slit 12 and the slope 13. In the container 11, a supply pipe 15 (supply means) is disposed above the slit 12 and parallel to the slit 12, and an introduction pipe in which both ends of the supply pipe 15 are respectively attached to left and right outer surfaces of the container 11. 16 and 17 are connected. The supply pipe 15 has a plurality of supply holes 18 opened downward. A gutter 19 for mixing and dispersing the paint is arranged in parallel with the slit 12 so as to accommodate the supply pipe 15.
(Mixing and dispersing means) is provided. As shown in FIG. 3, the gutter 19 has a U-shaped cross-sectional shape and has an upward opening 20.
【0015】次に、この塗料供給ヘッドを用いて分散、
溶解しにくい成分を含む塗料からなる塗料カーテンを形
成する方法について説明する。まず、図7に示されるよ
うな撹拌混合装置付きのタンク1で混合分散された塗料
2がポンプ3により導入管4(図1及び図2においては
導入管16、17)を通して定量的に層流のように塗料
供給ヘッド内に導入される。Next, dispersion is performed using the paint supply head.
A method for forming a paint curtain made of a paint containing a component that is difficult to dissolve will be described. First, the paint 2 mixed and dispersed in a tank 1 equipped with a stirring and mixing device as shown in FIG. 7 is quantitatively laminar-flowed by a pump 3 through an introduction pipe 4 (introduction pipes 16 and 17 in FIGS. 1 and 2). As shown in the drawing.
【0016】図1及び図2に示されるように、導入管1
6及び17を通して導入された塗料は供給管15内に入
り、複数の供給孔18から樋19内に供給される。この
とき、塗料はその流速により樋19の中に乱流のように
流出して分散、溶解しにくい成分が再び塗料内に均一に
分散されると共に、塗料の搬送経路中で巻き込んだ気泡
が除去される。このため、供給管15の供給孔18の位
置は、混合分散用の樋19に設けられた開口部20より
下に位置することが好ましい。As shown in FIG. 1 and FIG.
The paint introduced through 6 and 17 enters the supply pipe 15 and is supplied from a plurality of supply holes 18 into the gutter 19. At this time, the paint flows out into the gutter 19 like a turbulent flow due to the flow velocity, and the components that are difficult to disperse and dissolve are uniformly dispersed again in the paint, and the bubbles entrained in the transport path of the paint are removed. Is done. For this reason, it is preferable that the position of the supply hole 18 of the supply pipe 15 be located below the opening 20 provided in the mixing / dispersing gutter 19.
【0017】このようにして供給管15から樋19の中
に供給された塗料は樋上部の開口部20からスリット1
2と斜面部13とにより画成された塗料溜まり部14に
流出する。このとき、開口部20は分散、溶解しにくい
成分が再分散された塗料を塗料溜まり部14に均一に層
流のように流出させると共に塗料中に巻き込んだ空気に
よる気泡を除去する作用を有している。また、樋19の
外側面21は、開口部20より層流のように流出した塗
料がさらに均一に塗料溜まり部14に供給されると同時
に再び塗料中に巻き込んだ空気による気泡を除去する作
用を有している。なお、塗料溜まり部14に溜まってい
る塗料の液面22は樋19の下端から上端までの間にあ
ることが必要である。液面22が樋19の下端より下が
ると外側面21から塗料が滴下して気泡を巻き込みやす
くなり、樋19の上端より上がると塗料を開口部20か
ら外側面21に沿って層流のように流出させることがで
きなくなり、樋19の混合分散機能の発揮、及び塗料の
搬送経路中で巻き込んだ気泡を除去する機能の発揮が不
可能になるからである。In this manner, the paint supplied from the supply pipe 15 into the gutter 19 passes through the opening 20 in the upper part of the gutter and into the slit 1.
It flows out into the paint reservoir 14 defined by the slope 2 and the slope 13. At this time, the opening 20 has a function of uniformly discharging the paint in which the components which are hardly dispersed and dissolved to be re-dispersed into the paint reservoir 14 as a laminar flow, and removing bubbles caused by air entrained in the paint. ing. The outer surface 21 of the gutter 19 has a function of more uniformly supplying the paint flowing out from the opening 20 as a laminar flow to the paint reservoir 14 and at the same time removing air bubbles caused by air entrained in the paint. Have. The liquid level 22 of the paint stored in the paint reservoir 14 needs to be between the lower end and the upper end of the gutter 19. When the liquid level 22 falls below the lower end of the gutter 19, the paint drips from the outer surface 21, making it easier to entrain bubbles. When the liquid level 22 rises above the upper end of the gutter 19, the paint flows from the opening 20 along the outer surface 21 like a laminar flow. This is because it is impossible to flow out, and it becomes impossible to exhibit the mixing and dispersing function of the gutter 19 and the function of removing the air bubbles trapped in the paint transport path.
【0018】このようにして樋19の外側面21に沿っ
て塗料が塗料溜まり部14に流出することにより、塗料
溜まり部14内の塗料は再び均一に混合分散され、スリ
ット6、12により一定幅の薄いカーテン状またはフィ
ルム状の塗料カーテン7となって連続的に供給される。As described above, the paint flows out along the outer surface 21 of the gutter 19 into the paint reservoir 14, whereby the paint in the paint reservoir 14 is uniformly mixed and dispersed again. Is supplied continuously as a thin curtain-shaped or film-shaped paint curtain 7.
【0019】なお、供給管15の供給孔18は、塗料の
流速を利用して混合分散させることから樋19に流出す
る各供給孔18での塗料の流速又は流量が均一になるよ
うに形成することが好ましい。そこで、複数の供給孔1
8を、管内の塗料の流れ方向に対して上流側が疎に、下
流側が密になるような間隔で形成することが好ましい。
また、複数の供給孔18の代わりに供給管15にその長
さ方向に沿って下向きに開口するスリットを形成しても
よい。この場合には、管の長さ方向に沿ってスリットの
各部から流出する塗料の流速又は流量を均一にするため
に、管内の塗料の流れ方向に対して上流側が狭く、下流
側が広くなるような形状のスリットを形成することが好
ましい。The supply holes 18 of the supply pipe 15 are formed such that the flow velocity or the flow rate of the paint at each supply hole 18 flowing out to the gutter 19 is uniform since the mixture is dispersed by utilizing the flow velocity of the paint. Is preferred. Therefore, a plurality of supply holes 1
8 are preferably formed at intervals such that the upstream side is sparse and the downstream side is dense with respect to the flow direction of the paint in the pipe.
Further, instead of the plurality of supply holes 18, a slit that opens downward along the length direction of the supply pipe 15 may be formed. In this case, in order to make the flow velocity or the flow rate of the paint flowing out of each part of the slit along the length of the pipe uniform, the upstream side is narrower and the downstream side is wider with respect to the paint flow direction in the pipe. It is preferable to form a slit having a shape.
【0020】上記の実施の形態1においては、樋19の
断面形状をコ字状としたが、これに限るものではなく、
例えば図4に示されるように、U字状の断面形状を有す
る樋23を用いることもできる。その他、V字状やL字
状の断面形状の樋でもよい。ただし、塗料が塗料溜まり
部14に対して均一に且つ層流のように流出するように
樋を形成することが好ましい。このため、塗料溜まり部
14の液面22の上方に位置する樋の外側面は液面22
に対して直角あるいは鈍角をなすように形成されること
が好ましい。鋭角になると、外側面の上端あるいは途中
から塗料が滴下したり、流速や流量に偏りが発生して気
泡を巻き込みやすくなるからである。従って、図4に示
したU字状断面の樋23においては、樋23の外側面の
うち上部の鉛直部分24に液面22が位置することが好
ましい。In the first embodiment, the cross section of the gutter 19 has a U-shape. However, the present invention is not limited to this.
For example, as shown in FIG. 4, a gutter 23 having a U-shaped cross section may be used. In addition, a gutter having a V-shaped or L-shaped cross section may be used. However, it is preferable to form the gutter so that the paint flows out into the paint reservoir 14 uniformly and like a laminar flow. For this reason, the outer surface of the gutter located above the liquid level 22 of the paint reservoir 14
Is preferably formed at a right angle or an obtuse angle with respect to. When the angle is acute, the paint is dripped from the upper end or the middle of the outer surface, or the flow velocity or the flow rate is deviated, so that the bubbles are easily entrained. Therefore, in the gutter 23 having the U-shaped cross section shown in FIG. 4, it is preferable that the liquid surface 22 is located on the upper vertical portion 24 of the outer surface of the gutter 23.
【0021】また、図5に示されるように、下端部が斜
面部13の表面上に接触するような斜板25を設けると
共に斜面部13と斜板25とを接続する底板26を設け
て、斜面部13と斜板25と底板26とにより供給管1
5を収容する樋27を形成することもできる。さらに、
図6に示されるように、平面状の斜面部28をスリット
12の上部に連結形成すると共に容器11の内壁面29
を断面コ字状に屈曲させて斜面部28の背部に連結する
ことにより樋30を形成してもよい。As shown in FIG. 5, a swash plate 25 whose lower end is in contact with the surface of the slope portion 13 is provided, and a bottom plate 26 for connecting the slope portion 13 and the swash plate 25 is provided. The supply pipe 1 is formed by the slope 13, the swash plate 25, and the bottom plate 26.
A gutter 27 for accommodating 5 can also be formed. further,
As shown in FIG. 6, a flat slope 28 is formed on the upper portion of the slit 12 and the inner wall surface 29 of the container 11 is formed.
May be bent into a U-shaped cross section and connected to the back of the slope 28 to form the gutter 30.
【0022】この発明における塗料とは、従来から使用
されている塗料でもよく、何ら限定されるものではない
が、例えば分散、溶解しにくい成分を含む塗料、すなわ
ち界面活性作用あるいは濡れ性により塗料の樹脂成分に
分散しにくい着色顔料、体質顔料、骨材として添加する
微細粒子を含有する塗料、攪拌により分散し得るが静置
状態では塗料中の各成分が分離しやすい性質を有する塗
料、シリコーンオイル等を主成分とするはじき剤を添加
している塗料等を意味し、これらの塗料を用いた場合に
特に良好な塗料カーテンの形成に顕著な効果があり、良
好な塗膜を形成できる。The paint in the present invention may be a paint that has been used conventionally, and is not limited at all. For example, a paint containing a component which is hardly dispersed or dissolved, that is, a paint having a surface active action or wettability. Paints containing color pigments, extenders that are difficult to disperse in resin components, and fine particles added as aggregates, paints that can be dispersed by stirring but are easily separated from each other when left standing, silicone oil Means a paint or the like to which a repelling agent containing as a main component is added, and when these paints are used, it has a remarkable effect on formation of a particularly good paint curtain, and a good coating film can be formed.
【0023】実施の形態2. (化粧板の製造方法)基板の表面にこの発明の塗料供給
ヘッドを用いたフローコーターで塗料を塗布し、これを
硬化させて化粧層を形成することを特徴とする。この発
明における基板としては、材質や形状(板状に限らず)
など特に限定されるものではなく、いかなるものでもよ
いが、例えば、略平板状の金属板、無機質板、木質板、
紙板、樹脂板及びフィルム(薄板)などであり、無機質板
特に窯業系基板としては、セメント板、珪酸カルシウム
板、石膏ボード、スラグ石膏ボード、軽量コンクリート
板、およびそれらの繊維強化板、並びに木片セメント板
等が挙げられ、以下、基板として窯業系基板を、分散、
溶解しにくい成分を含む塗料としてはじき剤を添加した
化粧層形成用塗料を用いた意匠性に優れた窯業系化粧板
の製造方法を例に説明する。Embodiment 2 FIG. (Production method of decorative board) A paint is applied to the surface of a substrate by a flow coater using the paint supply head of the present invention, and is cured to form a decorative layer. The substrate in the present invention is made of a material or a shape (not limited to a plate).
It is not particularly limited and may be any, for example, a substantially flat metal plate, an inorganic plate, a wood plate,
Paper board, resin board and film (thin board), etc., inorganic board, especially ceramic-based board, cement board, calcium silicate board, gypsum board, slag gypsum board, lightweight concrete board, and their fiber reinforced board, and wood chip cement Plates and the like, below, ceramic substrate as a substrate, dispersed,
An example of a method for producing a ceramic decorative board having excellent design using a paint for forming a decorative layer to which a repellent is added as a paint containing a component that is difficult to dissolve will be described.
【0024】この発明における窯業系基板の表面形状
は、特に限定されるものではなく、フラット(略平板)
状、エンボス状(表面に凹凸を有する)等、製品として
得られる窯業系化粧板の目的とする用途、及び意匠性等
により適した形状を選定できる。本明細書中に記載して
いる窯業系基板の表面がフラット状とは、前記基板表面
に意図的に凹凸部を設けていない状態を意味しており、
前記基板における研磨処理の有無は特に限定されるもの
ではない。また、窯業系基板の表面がエンボス状とは、
前記基板製造時に、プレス加工、エンボスロール加工等
の公知の手法により意図的に基板表面部に凹凸を付与し
たものである。The surface shape of the ceramic substrate in the present invention is not particularly limited, and may be flat (substantially flat).
A shape suitable for the intended use of the ceramic decorative board obtained as a product, such as a shape, an embossed shape (having irregularities on the surface), and a design property can be selected. The flat surface of the ceramic substrate described in this specification means that the surface of the substrate is not intentionally provided with irregularities,
The presence or absence of the polishing treatment on the substrate is not particularly limited. Also, the surface of the ceramic substrate is embossed,
During the production of the substrate, irregularities are intentionally imparted to the surface of the substrate by a known method such as press working or embossing roll processing.
【0025】この発明における下地調整層とは、特に限
定されるものではないが、例えば窯業系基板表面部分の
補強(強度および硬度向上)のための層、窯業系基板が
化粧層に及ぼす影響の低減(例えば、アルカリ成分の化
粧層への侵入の低減)のための層、窯業系基板と化粧層
との密着性の向上および維持を図る目的で処理するため
の層、窯業系基板自体の色が、化粧板として仕上げた際
に影響が無くなるまで隠蔽することを目的とした層等で
ある。例えばシーラー処理、サーフェーサー処理、サン
ディング処理、下塗り処理(ベース塗装)等のことを指
す。なお、下地調整層は、前記のような各種目的の層を
得るために設けられるので、これらの処理は幾つかを組
合せて施してもよい。シーラー処理とは、窯業系基板表
面部分に含浸させて、表面部分の強度および硬度向上、
および窯業系基板と下地調整層の塗膜との密着性向上を
目的として行い、サーフェーサー処理とは、窯業系基板
表面の穴を埋め、さらに、使用する窯業系基板がアルカ
リ成分を含有する場合には、そのアルカリ成分が化粧層
等の塗膜層への侵入を抑制する目的で行う。また、サン
ディング処理とは窯業系基板表面における平滑性の向
上、および前記基板表面に残存する毛羽立ちの除去を図
る目的で行い、前記基板表面上に研磨しろ層を形成し、
研磨しろとなるサンディング層が硬化した後に前記基板
表面全体を均一に研磨仕上げすることである。前記研磨
工程で使用する研磨機の種類は特に限定されるものでは
なく、プラテン方式ベルトサンダー、ドラム方式ベルト
サンダー等の公知の装置を選定、使用できる。下塗り処
理(ベース塗装)とは、窯業系基板の色が化粧層に影響
を与えることのないように隠蔽し、窯業系基板と強固に
密着する役割を担っている。The undercoat adjustment layer in the present invention is not particularly limited, but is, for example, a layer for reinforcing (improving the strength and hardness) of the ceramic substrate surface portion and the effect of the ceramic substrate on the decorative layer. A layer for reducing (eg, reducing the penetration of alkali components into the decorative layer), a layer for treating and improving the adhesion between the ceramic substrate and the decorative layer, and the color of the ceramic substrate itself Is a layer or the like for the purpose of hiding until the effect is eliminated when finished as a decorative board. For example, it refers to a sealer process, a surfacer process, a sanding process, an undercoat process (base coating), and the like. Note that the base adjustment layer is provided in order to obtain layers for various purposes as described above, and these treatments may be performed in combination. Sealer treatment is to impregnate the ceramic substrate surface to improve the strength and hardness of the surface,
And the purpose of improving the adhesion between the ceramic substrate and the coating film of the base adjustment layer, surfacer treatment is to fill the holes in the ceramic substrate surface, and furthermore, when the ceramic substrate used contains an alkaline component Is performed for the purpose of suppressing the alkali component from entering the coating layer such as the decorative layer. In addition, the sanding treatment is performed for the purpose of improving the smoothness on the ceramic substrate surface, and removing fuzz remaining on the substrate surface, forming a polishing margin layer on the substrate surface,
After the sanding layer to be polished is hardened, the entire surface of the substrate is uniformly polished. The type of polishing machine used in the polishing step is not particularly limited, and a known device such as a platen type belt sander or a drum type belt sander can be selected and used. The undercoating (base coating) plays a role of hiding the ceramic substrate so that the color of the substrate does not affect the decorative layer and firmly adhering to the ceramic substrate.
【0026】下地調整層に用いられる材料は、化粧層と
の密着性を損なわない組成を有するものであれば、特に
限定されるものでなく、一般に用いられているウレタン
系樹脂、アクリルウレタン系樹脂、不飽和ポリエステル
系樹脂、ポリエステルアクリレート系樹脂、アクリルエ
ポキシ系樹脂、アクリル系樹脂、ポリウレタン系樹脂、
アクリルポリウレタン系樹脂等を適用できる。下地調整
層の塗布方法についても特に限定されるものではなく、
スプレー法、ロールコーター法、フローコーター法等、
通常の塗装において使用される公知の方法から、使用す
る材料に適した方法を選定できる。この発明における化
粧層とは、樹脂や顔料を主成分とする化粧層形成用塗料
にはじき剤を添加して塗布、硬化することにより形成さ
れる層である。The material used for the base adjustment layer is not particularly limited as long as it has a composition that does not impair the adhesion to the decorative layer, and generally used urethane resins and acrylic urethane resins , Unsaturated polyester resin, polyester acrylate resin, acrylic epoxy resin, acrylic resin, polyurethane resin,
Acrylic polyurethane resin or the like can be applied. The method of applying the base adjustment layer is not particularly limited, either.
Spray method, roll coater method, flow coater method, etc.
A method suitable for the material to be used can be selected from known methods used in ordinary coating. The decorative layer in the present invention is a layer formed by adding a repelling agent to a decorative layer forming paint containing a resin or a pigment as a main component, and applying and curing the paint.
【0027】また、本発明における窯業系化粧板の製造
方法は、混合分散しにくい成分としてはじき剤を用い、
このはじき剤の添加量が、例えば化粧層形成用塗料の全
固形分に対して0.1〜1.2質量%の範囲とするもの
である。この発明におけるはじき剤とは、化粧層に不均
一な相を生じせしめる物質を意味する。ここでいう不均
一な相とは、化粧層における例えば樹脂の密度が不均一
である;含まれる顔料の密度が不均一である;それゆえ
光線反射率または光線拡散率も変化が生じる;等を指
す。不均一な相は、はじき剤のはじき効果(はじき剤と
その他の物質が反発する効果)により形成される。はじ
き剤を添加した化粧層形成用塗料のレベリング性が阻害
され、塗膜の表面に凹凸模様が形成され、塗膜厚が変化
し、塗膜中の顔料の配向方向または分散密度が変化す
る。これにより、意匠性、特に光揮感、立体感、陰影
感、深み感に優れた窯業系化粧板を製造することができ
る。In the method for producing a ceramic decorative panel according to the present invention, a repellent is used as a component which is difficult to mix and disperse.
The amount of the repellent added is, for example, in the range of 0.1 to 1.2% by mass based on the total solid content of the paint for forming a decorative layer. The repellent agent in the present invention means a substance which causes an uneven phase in the decorative layer. The non-uniform phase as used herein means, for example, that the density of the resin in the decorative layer is non-uniform; the density of the pigment contained in the decorative layer is non-uniform; Point. The heterogeneous phase is formed by the repelling effect of the repellent (the effect of repelling the repellent and other substances). The leveling property of the paint for forming a decorative layer to which the repellent is added is impaired, an uneven pattern is formed on the surface of the coating film, the thickness of the coating film changes, and the orientation direction or dispersion density of the pigment in the coating film changes. This makes it possible to manufacture a ceramic decorative panel excellent in design properties, in particular, a feeling of luminosity, a three-dimensional effect, a shadow effect, and a sense of depth.
【0028】はじき剤の種類は化粧層を構成するその他
の材料等を勘案して適宜決定すればよいが、例えばシリ
コーンオイル等を用いることができる。また、選定した
シリコーンオイルの粘度が高く、化粧層形成用塗料中へ
の分散が困難な場合においては、化粧層形成用塗料に悪
影響を及ぼさない希釈用溶剤等を用いて希釈した後に使
用してもよい。また、はじき剤の添加量は、化粧層を塗
布する際の下地調整層を施した窯業系基板の表面温度や
はじき剤を添加した化粧層形成用塗料の粘度等により相
違するものであるが、例えば化粧層形成用塗料の全固形
分に対して、3質量%まで添加できる。また、化粧層上
に透明または半透明のトップクリア層を形成する際に、
化粧層表面部に存在するはじき剤の作用により、塗着ま
たは接着した透明または半透明のトップクリア層までも
部分的にはじかせる塗膜不良を来す場合もあるので適宜
選択して使用できる。The type of the repelling agent may be appropriately determined in consideration of other materials constituting the decorative layer, and for example, silicone oil or the like may be used. If the selected silicone oil has a high viscosity and is difficult to disperse in the decorative layer forming paint, use it after diluting with a diluting solvent that does not adversely affect the decorative layer forming paint. Is also good. In addition, the amount of the repellent added is different depending on the surface temperature of the ceramic substrate to which the base adjustment layer is applied when applying the decorative layer, the viscosity of the decorative layer forming paint to which the repellent is added, and the like. For example, up to 3% by mass can be added to the total solid content of the paint for forming a decorative layer. Also, when forming a transparent or translucent top clear layer on the decorative layer,
Due to the action of the repellent agent present on the surface of the decorative layer, even a coated or adhered transparent or translucent top clear layer sometimes causes a defective coating to partially repel, so that it can be appropriately selected and used.
【0029】本発明において使用する化粧層形成用塗料
は、顔料を含有しているものであってもよい。顔料とし
ては、パール、雲母、アルミニウム粉等の金属粉等の鱗
片状の顔料が好ましい。このような鱗片状の顔料は、は
じき剤によるはじき効果により配向方向または分散密度
が化粧層中で変化し、光輝感、立体感、陰影感、深み感
を付与することができる。顔料の含有量は、例えば化粧
層形成用塗料の全固形分に対して内割りで10質量%ま
で添加できるが、意匠の深み感への寄与、塗装装置、あ
るいは塗料の循環、経路部分で分散不良や沈殿を起こし
たり、また化粧層形成用塗料が紫外線硬化型塗料の場合
には、紫外線硬化時に紫外線が顔料により遮蔽され、硬
化不良を来す場合もあるので適宜選択して使用できる。The paint for forming a decorative layer used in the present invention may contain a pigment. As the pigment, scaly pigments such as pearl, mica, and metal powder such as aluminum powder are preferable. Such a scaly pigment changes the orientation direction or the dispersion density in the decorative layer due to the repelling effect of the repelling agent, and can impart a glittering effect, a three-dimensional effect, a shadow effect, and a depth effect. The pigment content can be added, for example, up to 10% by mass with respect to the total solid content of the paint for forming a decorative layer. If the paint for forming the decorative layer is an ultraviolet-curable paint, the pigment may block ultraviolet rays during the ultraviolet-curing process, which may result in poor curing.
【0030】化粧層形成用塗料の具体的な硬化方法は、
バインダーとして使用する樹脂の種類により異なるが、
熱硬化型、紫外線硬化型、または電子線硬化型が好適で
ある。熱硬化型塗料とは溶剤揮発後、加熱により架橋、
あるいは触媒・硬化剤の作用により重合するものを示
し、具体的には顔料、樹脂、添加剤、溶剤等の成分から
構成される塗料である。紫外線硬化型塗料とは、紫外線
の照射により光重合開始剤からラジカルを発生すること
により、光重合性化合物が連鎖的に重合反応するものを
示し、具体的には光重合性の樹脂、オリゴマー、反応性
希釈溶剤、光重合開始剤(光増感剤)等の成分から構成
される塗料である。該塗料に使用される樹脂としては、
不飽和ポリエステル系樹脂、ポリエステルアクリレート
系樹脂、アクリルエポキシ系樹脂、アクリル樹脂、アク
リルポリウレタン系樹脂等が挙げられる。電子線硬化型
塗料は、主として強エネルギーである電子線を照射し、
直接重合性化合物の不飽和基に作用して重合するものを
示し、具体的には不飽和ポリエステル系樹脂、エポキシ
アクリレート系樹脂、ウレタンアクリレート系樹脂、ポ
リエステルアクリレート系樹脂、ポリエーテルアクリレ
ート系樹脂、不飽和アクリル系樹脂等が挙げられる。化
粧層の厚さはとくに制限されるものではなく、窯業系基
板の表面形状にもよるが例えば10〜100μmであ
る。The specific curing method of the paint for forming the decorative layer is as follows.
It depends on the type of resin used as the binder,
A thermosetting type, an ultraviolet curable type, or an electron beam curable type is preferable. After the solvent is evaporated from the thermosetting paint, it is crosslinked by heating.
Alternatively, it indicates a substance which is polymerized by the action of a catalyst / curing agent, and specifically, is a paint composed of components such as pigments, resins, additives, and solvents. Ultraviolet-curable coatings are those in which photopolymerizable compounds undergo a chain polymerization reaction by generating radicals from a photopolymerization initiator upon irradiation with ultraviolet light, and specifically include photopolymerizable resins, oligomers, It is a paint composed of components such as a reactive diluent solvent and a photopolymerization initiator (photosensitizer). As the resin used for the paint,
Examples include unsaturated polyester resins, polyester acrylate resins, acrylic epoxy resins, acrylic resins, and acrylic polyurethane resins. Electron beam-curable coatings mainly irradiate strong energy electron beams,
Shows those which polymerize by acting directly on the unsaturated groups of the polymerizable compound, specifically, unsaturated polyester resins, epoxy acrylate resins, urethane acrylate resins, polyester acrylate resins, polyether acrylate resins, And a saturated acrylic resin. The thickness of the decorative layer is not particularly limited, and is, for example, 10 to 100 μm although it depends on the surface shape of the ceramic substrate.
【0031】この発明における化粧板の製造方法は、窯
業系基板の表面温度を60〜90℃に調整し、窯業系基
板の表面上に下地調整層を設け、続いて窯業系基板の表
面温度を50〜80℃に調整した後、はじき剤を添加し
た化粧層形成用塗料をこの発明の塗料供給ヘッドにより
下地調整層上に塗着および硬化させて化粧層を設け、さ
らに透明または半透明の硬化樹脂塗料を前記化粧層上に
塗着および硬化させて透明または半透明のトップクリア
層を形成することにより得ることができる。In the method for manufacturing a decorative board according to the present invention, the surface temperature of the ceramic substrate is adjusted to 60 to 90 ° C., a base adjustment layer is provided on the surface of the ceramic substrate, and then the surface temperature of the ceramic substrate is reduced. After the temperature is adjusted to 50 to 80 ° C., a paint for forming a decorative layer to which a repellent is added is applied and cured on the base adjustment layer by the paint supply head of the present invention to provide a decorative layer, and further, a transparent or translucent curing It can be obtained by applying and curing a resin paint on the decorative layer to form a transparent or translucent top clear layer.
【0032】また、下地調整層を施した化粧層塗布前の
窯業系基板の予備加熱による表面温度は50〜80℃が
好ましい。表面温度が50℃未満であると例えばはじき
剤を添加した熱硬化型の化粧層形成用塗料により化粧層
を塗布した際に化粧層の樹脂が硬化しにくく、はじき剤
を添加した化粧層形成用塗料が流動性を失う(定着)ま
で時間が長く、柄および模様の再現性が得られないこと
がある。また、化粧層形成用塗料に添加したはじき剤の
作用で、当初は化粧層表面に凹凸模様が得られるもの
の、はじき剤を添加した化粧層形成用塗料が流動性を保
っているため逆にレベリングが進行し、部分的、あるい
は全体的に形成した模様が崩壊あるいは変化し、柄強い
ては模様の再現性が得られないばかりか、立体感、深み
感に欠けるようになる。予備加熱による表面温度が80
℃を超えると発泡、ふくれ、ワキ等の塗膜異常を来たし
たり、また、はじき剤を添加した化粧層形成用塗料が熱
硬化型の場合には、はじき剤が作用し、化粧層表面に凹
凸模様が得られる前に塗布された該塗料の流動性が急激
に低下するため好ましくない。 なお、予備加熱の方法
としては、赤外ランプ式乾燥機、遠赤外ランプ式乾燥
機、直接熱風式乾燥機、間接熱風式乾燥機等の加温装置
を用いることができ、下地調整層およびはじき剤を添加
した化粧層形成用塗料のレベリングおよび硬化を促進す
ることができる。また、前記では窯業系基板を加熱して
いるが、これを行わず塗料を塗布後にのみ乾燥硬化させ
ただけでは気温の変化に伴い、はじき効果も変動して柄
や模様も変動し、化粧層の表面の凹凸の大きさが変化
し、安定した生産ができないので好ましくない。Further, the surface temperature of the ceramic substrate before the application of the decorative layer provided with the base adjustment layer by preheating is preferably 50 to 80 ° C. When the surface temperature is less than 50 ° C., for example, when the decorative layer is applied with a thermosetting type decorative layer forming paint to which a repelling agent is added, the resin of the decorative layer is hardly cured, and the repelling agent is added to the decorative layer forming. It takes a long time until the paint loses fluidity (fixation), and the reproducibility of the pattern and the pattern may not be obtained. In addition, the effect of the repellent added to the paint for forming the decorative layer initially gives an uneven pattern on the surface of the decorative layer, but the paint for forming the decorative layer to which the repellent is added retains the fluidity, and conversely, leveling occurs. Progresses, the pattern formed partially or entirely collapses or changes, and if the pattern is strong, not only the reproducibility of the pattern is not obtained, but also the three-dimensional appearance and the sense of depth are lacking. Surface temperature by preheating is 80
If the temperature exceeds ℃, foaming, swelling, and coating film abnormalities may occur, and if the decorative layer forming paint to which the repellent is added is a thermosetting type, the repellent acts to cause irregularities on the surface of the decorative layer. It is not preferable because the fluidity of the coating applied before the pattern is obtained rapidly decreases. In addition, as a method of preheating, a heating device such as an infrared lamp dryer, a far infrared lamp dryer, a direct hot air dryer, an indirect hot air dryer can be used. Leveling and curing of the decorative layer forming paint to which the repellent is added can be promoted. Further, in the above, the ceramic substrate is heated, but if this is not performed and only the coating is dried and hardened only after the application of the coating, the repelling effect fluctuates and the pattern and pattern fluctuate with the change in temperature, and the decorative layer The size of the surface irregularities changes, and stable production cannot be performed, which is not preferable.
【0033】また、本発明において下地調整層を施した
窯業系基板にはじき剤を添加した化粧層形成用塗料を一
般に市販されている塗料供給手段と混合分散手段のない
塗料供給ヘッドにて塗装しようとした場合、塗料供給ヘ
ッド側面部に位置する導入管17より塗料供給ヘッド内
部に前記塗料が落下する際に、前記塗料中に気泡を巻き
込んだり、あるいは巻き込んだ気泡を包含した状態とな
る。市販されている塗料供給ヘッドはその構造上、塗料
供給ヘッド内部に塗料が滞留する時間が短く、前記塗料
中に気泡を包含した状態で塗料が流下し、スリット12
より塗料カーテンとして流出するため、「カーテン切
れ」を生じ、塗装不良が頻発する理由により使用不可能
である。一方、本発明の塗料供給ヘッドを用いた場合、
該塗料供給ヘッド内部ではじき剤を添加した化粧層形成
用塗料中に気泡の巻き込みがなく、また、混合攪拌装置
付きのタンク1にて一度分散混合させたはじき剤を添加
した化粧層形成用塗料を塗料供給ヘッド内部で、はじき
剤成分と化粧層形成用塗料とを再度良く混合分散(なじ
ませる)させた後、塗料が流下するスリット12から塗
料カーテンとして落下する迄の時間を遅らせる構造とし
ているため、塗料供給ヘッド内での塗料流を安定させる
ことができ、均一な塗料カーテンを得ることができるた
め好適である。Further, in the present invention, a paint for forming a decorative layer to which a repellent is added is applied to a ceramic substrate provided with an undercoat adjustment layer by a paint supply head which is generally not provided with a paint supply means and a mixing and dispersing means. In this case, when the paint falls into the paint supply head from the introduction pipe 17 located on the side of the paint supply head, bubbles are entrained in the paint, or the entrained bubbles are contained. Due to the structure of the commercially available paint supply head, the time for which the paint stays inside the paint supply head is short, and the paint flows down in a state in which bubbles are contained in the paint.
Since it flows out more as a paint curtain, "curtain break" occurs, and the paint cannot be used due to frequent coating defects. On the other hand, when the paint supply head of the present invention is used,
Inside the paint supply head, there is no entrapment of air bubbles in the paint for forming a decorative layer to which a repellent has been added, and the paint for forming a decorative layer to which a repellent has been added once dispersed and mixed in a tank 1 equipped with a mixing and stirring device. After the repelling agent component and the paint for forming the decorative layer are mixed and dispersed (mixed) well again inside the paint supply head, the time required for the paint to fall as a paint curtain from the slit 12 through which the paint flows down is delayed. Therefore, it is preferable because the paint flow in the paint supply head can be stabilized and a uniform paint curtain can be obtained.
【0034】また、この発明の塗料供給ヘッド内におけ
る塗料の液面22は、混合分散手段側部の開口部から混
合分散手段の最下部までの範囲に維持する必要がある。
上記塗料供給ヘッド内における塗料の液面22が混合分
散手段の最下部より下にある場合、混合分散手段から塗
料が液面22、或いは塗装ヘッド内の斜面部に落下する
際に塗料流の乱れ、気泡の巻き込みを生じ、塗料カーテ
ンが不安定となり「カーテン切れ」を生じる恐れがある
ため好ましくない。一方、上記塗料供給ヘッド内におけ
る塗料の液面22が混合分散手段の開口部より上にある
場合、塗料中に気泡が混入した際に、気泡を除去(脱
泡)する効果が得られにくいため、好ましくない。The liquid level 22 of the paint in the paint supply head according to the present invention must be maintained in a range from the opening on the side of the mixing and dispersing means to the lowermost portion of the mixing and dispersing means.
When the liquid level 22 of the paint in the paint supply head is below the lowermost part of the mixing and dispersing means, when the paint falls from the mixing and dispersing means to the liquid level 22 or the slope in the coating head, the flow of the paint is disturbed. This is not preferable because bubbles may be entrained and the paint curtain may become unstable and "cut curtain" may occur. On the other hand, when the liquid level 22 of the paint in the paint supply head is above the opening of the mixing and dispersing means, when bubbles are mixed in the paint, the effect of removing (defoaming) bubbles is hardly obtained. Is not preferred.
【0035】また、本発明における上記塗料供給ヘッド
を用いたときのはじき剤を添加した化粧層形成用塗料の
塗布量は、はじき剤の添加量、はじき剤を添加した化粧
層形成用塗料粘度、スリット幅、コンベアの速度、スリ
ットからの吐出量などの塗装条件にもよるが、例えば岩
田#2カップで測定時の粘度が30秒、基板搬送用コン
ベアの速度が80m/min、スリット幅が0.8mm
の条件下においては、60〜200g/m2、好ましく
は70〜150g/m2である。塗布量が60g/m2以
下では、塗料供給ヘッド内での塗料の液面が混合分散手
段の最下部より下に位置するため、塗料カーテンが不安
定となり、「カーテン切れ」を生じる要因となるため好
ましくない。塗布量が200g/m2より多い場合、化
粧層形成用塗料に添加したはじき剤の作用により得られ
る柄、及び模様の再現性が得にくいため好ましくない。
また、塗装条件によっては、塗料供給ヘッド内における
塗料の液面が混合分散手段の開口部より上に位置するた
め、塗料循環経路内で巻き込んだ気泡の除去性が低下す
るため好ましくない。なお、本明細書中に記載している
塗布量とは、窯業系基板に塗布した直後(未硬化状態)
における単位面積当たりに塗着した塗料の質量を意味す
る。When the paint supply head according to the present invention is used, the coating amount of the decorative layer forming paint to which the repelling agent is added is determined by the amount of the repelling agent added, the viscosity of the decorative layer forming paint to which the repelling agent is added, Although it depends on the coating conditions such as the slit width, the speed of the conveyor, and the amount of discharge from the slit, for example, the viscosity at the time of measurement with an Iwata # 2 cup is 30 seconds, the speed of the substrate conveyor is 80 m / min, and the slit width is 0 .8mm
Under the conditions described above, the amount is 60 to 200 g / m 2 , preferably 70 to 150 g / m 2 . When the coating amount is 60 g / m 2 or less, the liquid level of the paint in the paint supply head is located below the lowermost part of the mixing and dispersing means, so that the paint curtain becomes unstable and causes “cut curtain”. Therefore, it is not preferable. If the coating amount is more than 200 g / m 2, it is not preferable because the pattern obtained by the action of the repellent added to the paint for forming a decorative layer and the reproducibility of the pattern are difficult to obtain.
Further, depending on the coating conditions, the liquid level of the paint in the paint supply head is located above the opening of the mixing and dispersing means, which is not preferable because the removability of bubbles entrained in the paint circulation path is reduced. In addition, the coating amount described in this specification is immediately after coating on a ceramic substrate (uncured state)
Means the mass of the paint applied per unit area.
【0036】また、上記塗料供給ヘッドで塗装する際に
おけるはじき剤を添加した化粧層形成用塗料の粘度は、
岩田#2カップで20秒〜50秒の範囲に調整する。ま
たスリットの幅は、特に限定されるものでなく、一般的
に市販されているフローコーターと同様に0.5mm〜
0.8mmの範囲に調整することが好ましい。塗料流下
スリットの最下部から基板搬送用コンベアまでの距離は
100mmから200mmの範囲が好ましく、さらに、
上記フローコーターでの基板搬送用コンベアの速度につ
いても、特に限定されるものではない。The viscosity of the paint for forming a decorative layer to which a repelling agent is added at the time of coating with the paint supply head is as follows:
Adjust with Iwata # 2 cup in the range of 20-50 seconds. The width of the slit is not particularly limited, and 0.5 mm to 0.5 mm, similar to a generally commercially available flow coater.
It is preferable to adjust to a range of 0.8 mm. The distance from the lowermost part of the paint flow-down slit to the substrate transfer conveyor is preferably in the range of 100 mm to 200 mm,
The speed of the substrate transport conveyor in the flow coater is not particularly limited.
【0037】この発明における透明または半透明のトッ
プクリヤー層とは、化粧層上に形成される層であって、
全光線透過率が40%以上、より好ましくは50%以上
の層を意味する。全光線透過率はヘイズメーター等を用
いて従来公知の方法で測定することができる。また、透
明または半透明のトップクリヤー層は、化粧層の保護層
としての役割を果たすとともに、更なる深み感・立体感
を付与するものである。透明または半透明のトップクリ
ヤー層は、塗装後硬化することにより透明または半透明
の塗膜層を形成する塗料を化粧層上に塗布し硬化させる
方法、あるいは透明または半透明のフィルムを化粧層上
に接着して形成する方法等により形成される。トップク
リヤー層形成用の塗料は、特に限定されるものではな
く、例えば、ウレタン系、アクリル系、アクリルウレタ
ン系、不飽和ポリエステル系、ウレタンアクリレート系
等の熱硬化型樹脂塗料、紫外線硬化型樹脂塗料、電子線
硬化型樹脂塗料等からなる無色透明塗料あるいは着色顔
料を含ませた半透明塗料を用いることができる。トップ
クリヤー層形成用塗料として、樹脂塗料に着色顔料を添
加して使用する場合には、例えば、前記樹脂塗料に対
し、0.3〜4質量%、好ましくは0.8〜2質量%が
よい。トップクリヤー層形成用塗料の塗布方法は、ロー
ルコーター法、フローコーター法がとくに好ましいが、
その他スプレー法、転写法等の既存の方法を用いてもよ
い。また、トップクリヤー層の厚さはとくに制限されな
いが、15〜100μmである。The transparent or translucent top clear layer in the present invention is a layer formed on a decorative layer,
It means a layer having a total light transmittance of 40% or more, more preferably 50% or more. The total light transmittance can be measured by a conventionally known method using a haze meter or the like. Further, the transparent or translucent top clear layer serves as a protective layer for the decorative layer and imparts a further sense of depth and depth. Transparent or translucent top clear layer is a method of applying a paint that forms a transparent or translucent coating layer by curing after painting on the decorative layer and curing, or a transparent or translucent film on the decorative layer It is formed by, for example, a method of adhering to the substrate. The coating material for forming the top clear layer is not particularly limited. For example, thermosetting resin coating materials such as urethane, acrylic, acrylic urethane, unsaturated polyester, and urethane acrylate resins, and ultraviolet curing resin coatings A colorless transparent paint made of an electron beam-curable resin paint or a translucent paint containing a coloring pigment can be used. In the case where a coloring pigment is added to a resin coating and used as the top clear layer forming coating, for example, 0.3 to 4% by mass, preferably 0.8 to 2% by mass based on the resin coating is good. . As a method of applying the top clear layer forming paint, a roll coater method and a flow coater method are particularly preferable,
In addition, existing methods such as a spray method and a transfer method may be used. Although the thickness of the top clear layer is not particularly limited, it is 15 to 100 μm.
【0038】[0038]
【実施例】以下、本発明の実施例について説明する。 (実施例1)抄造法によって製造した未硬化の繊維強化
セメント板の表面に、凹凸を有するFRP製の型板の凹
凸面を当接させて加圧した後、80℃で8時間スチーム
養生を行うことにより反応硬化させ、前記型板を取り外
した後乾燥して、凸部から凹部までの深さが100μm
の凹凸部を有する窯業系基板を作製した。次に、前記基
板の表面温度を予め60℃に調整し、その上に下地調整
層としてアクリルウレタン系塗料(大阪ワニス(株)製
220コニタン下塗り)をロールコーターで40g/m
2、従来のフローコーターで160g/m2(80g/m
2×2回塗り)、計200g/m2塗布し、その後表面温
度80℃で5分間乾燥硬化させた。Embodiments of the present invention will be described below. (Example 1) After pressing the surface of an uncured fiber reinforced cement board manufactured by a papermaking method with the uneven surface of an FRP mold plate having unevenness and pressing, steam curing was performed at 80 ° C for 8 hours. The reaction is cured by performing, the mold plate is removed and then dried, and the depth from the convex portion to the concave portion is 100 μm.
A ceramic substrate having irregularities was prepared. Next, the surface temperature of the substrate was previously adjusted to 60 ° C., and an acrylic urethane-based paint (underlying 220 conitane manufactured by Osaka Varnish Co., Ltd.) was applied thereon as a base adjustment layer by a roll coater at 40 g / m 2.
2 , 160 g / m 2 (80 g / m 2 )
2 × 2 coatings), a total of 200 g / m 2 was applied, and then dried and cured at a surface temperature of 80 ° C. for 5 minutes.
【0039】かかる後、塗装面における塗装不良発生の
有無について評価を行った。続いて、表面温度を60℃
に調整した下地調整層を施した窯業系基板上に、平均粒
径50μmの鱗片状のパール顔料を5質量%含有したア
クリルウレタン系塗料(大阪ワニス(株)製220コニ
タン上塗りブライトーンシルバー)にシリコーンオイル
を主成分とするはじき剤を化粧層形成用塗料の全固形分
に対して0.5質量%添加した化粧層形成用塗料を本発
明の塗料供給ヘッドを用いたフローコーターで80g/
m2塗布し、その後80℃で20分間乾燥した。上記フ
ローコーターにおける塗料供給ヘッドでの塗装条件は、
導入管から塗装ヘッドへの化粧層形成用塗料の供給は幅
方向の2箇所(16,17の位置)からとし、スリット
の幅は0.8mm、スリットから基板搬送用コンベアま
での距離は100mm、基板搬送用コンベア速度は80
m/分、はじき剤を添加した化粧層形成用塗料の粘度は
30秒(岩田#2カップでの測定値)とした。また、塗
料供給ヘッド内への塗料の流入量は6.3kg/min
とした。After that, an evaluation was made as to whether or not a coating defect occurred on the coated surface. Subsequently, the surface temperature was set to 60 ° C.
Acrylic urethane paint (Osaka Varnish 220 Brighton Silver overcoat) containing 5% by mass of a flaky pearl pigment with an average particle size of 50 μm on a ceramic substrate provided with a base adjustment layer adjusted to A paint for forming a decorative layer obtained by adding a repellent agent containing silicone oil as a main component to the total solid content of the paint for forming a decorative layer in an amount of 0.5% by mass with a flow coater using the paint supply head of the present invention was 80 g /.
m 2 and then dried at 80 ° C. for 20 minutes. The coating conditions for the paint supply head in the flow coater are as follows:
The supply of the paint for forming the decorative layer from the inlet pipe to the coating head is performed at two positions (positions 16 and 17) in the width direction, the width of the slit is 0.8 mm, the distance from the slit to the substrate transport conveyor is 100 mm, Conveyor speed for substrate transfer is 80
The viscosity of the paint for forming a decorative layer to which the repellent was added was 30 seconds (measured value with Iwata # 2 cup). The amount of paint flowing into the paint supply head is 6.3 kg / min.
And
【0040】はじき剤を添加した化粧層形成用塗料を上
記塗料供給ヘッドを用いたフローコーターで塗装する際
における塗料カーテン安定性の評価は、一般的にフロー
コーター式塗装装置では、フローコーター、及び塗料循
環ポンプ装置を始動させた直後は、塗料カーテンが不安
定となりやすく、正当な評価を行いにくいため、はじき
剤を添加した化粧層形成用塗料を塗装する条件にて、フ
ローコーター、及び塗料循環ポンプ装置を始動させ、1
0分経過した時点から目視で塗料カーテンを5分間観察
し、5分間の観察時間内における「カーテン切れ」回数
を計測する方法とした。なお、塗料カーテンの目視観察
は、見逃し、数え間違い等を防止するため5人で実施
し、5人の計測回数における最大値と最小値とを除外し
た3つの値の平均で表した。また、化粧層形成用塗料の
塗装面における塗装不良発生の有無について評価も併せ
て行った。Evaluation of the stability of a paint curtain when a paint for forming a decorative layer to which a repellent agent is added is applied by a flow coater using the above-described paint supply head is generally performed by a flow coater type coating apparatus using a flow coater and a flow coater. Immediately after starting the paint circulation pump device, the paint curtain is likely to be unstable, making it difficult to make a valid evaluation. Start the pump device, 1
The paint curtain was visually observed for 5 minutes from the time when 0 minutes had elapsed, and the number of “curtain breaks” within the 5-minute observation time was measured. In addition, the visual observation of the paint curtain was performed by five persons in order to prevent oversight, miscounting and the like, and was represented by an average of three values excluding the maximum value and the minimum value in the number of times of measurement by five persons. In addition, the presence or absence of coating failure on the painted surface of the paint for forming a decorative layer was also evaluated.
【0041】続いて透明硬化樹脂として全光線透過率が
89%の紫外線硬化樹脂塗料(大阪ワニス(株)製70
0バイオレンクリア509H)をフローコーターで10
0g/m2塗布し、40℃雰囲気中で5分間セッティン
グした後に、6m/分にて移動させながら、80W/c
m×2灯の条件で紫外線を照射し硬化させた。かかる
後、目視による外観観察での光輝感、立体感、陰影感、
深み感の評価、及び塗装面における塗装不良発生の有無
について評価を行った。Subsequently, as a transparent curable resin, an ultraviolet curable resin paint having a total light transmittance of 89% (manufactured by Osaka Varnish Co., Ltd., 70)
0 biolen clear 509H) with a flow coater for 10
After applying 0 g / m 2 and setting in a 40 ° C. atmosphere for 5 minutes, while moving at 6 m / min, 80 W / c
Ultraviolet rays were irradiated under the condition of mx2 lamps to cure. After this, the luminosity, three-dimensional feeling, shading,
The evaluation of the feeling of depth and the presence / absence of coating failure on the painted surface were evaluated.
【0042】(実施例2)表面形状がフラット状の窯業
系基板とし、下地調整層を施した窯業系基板の表面温度
を75℃としたこと以外は実施例1と同様に行った。Example 2 The same procedure as in Example 1 was carried out except that a ceramic substrate having a flat surface shape was used, and the surface temperature of the ceramic substrate provided with the base adjustment layer was 75 ° C.
【0043】(実施例3)予備加熱温度を70℃、パー
ル顔料の平均粒度を110μm、はじき剤を使用しなか
ったこと以外は実施例1と同様に行った。Example 3 The same procedure as in Example 1 was carried out except that the preheating temperature was 70 ° C., the average particle size of the pearl pigment was 110 μm, and no repelling agent was used.
【0044】(実施例4)基板を繊維強化珪酸カルシウ
ム板、凹凸深さを120μm、塗料をUV硬化型樹脂塗
料、パール顔料の平均粒度を100μm、パール顔料の
添加量を4質量%とした以外は実施例1と同様に行っ
た。Example 4 A substrate was a fiber-reinforced calcium silicate plate, the depth of irregularities was 120 μm, the coating was a UV-curable resin coating, the average particle size of the pearl pigment was 100 μm, and the addition amount of the pearl pigment was 4% by mass. Was performed in the same manner as in Example 1.
【0045】(比較例1)はじき剤を添加した化粧層形
成用塗料を、一般的に市販されている供給手段及び混合
分散手段を備えていない従来の塗料供給ヘッドを使用し
たこと以外は、実施例1と同様に行った。(Comparative Example 1) A paint for forming a decorative layer to which a repellent was added was prepared in the same manner as in the case of using a conventional paint supply head without a commercially available supply means and a mixing and dispersing means. It carried out like Example 1.
【0046】(比較例2)はじき剤を添加した化粧層形
成用塗料を、特開平11−128803号公報記載の塗
料供給ヘッドを使用したこと以外は、実施例1と同様に
行った。(Comparative Example 2) A paint for forming a decorative layer to which a repellent was added was prepared in the same manner as in Example 1 except that a paint supply head described in JP-A-11-128803 was used.
【0047】実施例1〜4及び比較例1及び2の評価結
果を氷に示す。なお、表1において、化粧層の形成条件
において「表面温度」とあるのは窯業系下地調整層を施
した窯業系基板の表面温度を意味している。The evaluation results of Examples 1 to 4 and Comparative Examples 1 and 2 are shown on ice. In Table 1, “surface temperature” in the conditions for forming the decorative layer means the surface temperature of the ceramic substrate provided with the ceramic base adjustment layer.
【0048】[0048]
【表1】 [Table 1]
【0049】[0049]
【発明の効果】以上説明したように、この発明によれ
ば、混合分散または混合溶解しにくい成分を含む塗料で
あっても、安定した塗料カーテンを形成してカーテン切
れがなく且つ混合分散または混合溶解しにくい成分の偏
りがなく、塗料を均一に塗装することが可能となる。さ
らに、この発明の塗料供給ヘッドを用いることにより、
塗装不良もなく、柄および模様の再現性に優れた製品の
製造が可能であり、しかも表面の硬度が高く、意匠性、
特に光揮感、立体感、陰影感、深み感に優れた化粧板を
製造することが可能となる。As described above, according to the present invention, even a paint containing a component which is hardly mixed or dispersed or mixed and dissolved, a stable paint curtain is formed, the curtain is not broken, and the mixed and dispersed or mixed There is no bias in the components that are difficult to dissolve, and it is possible to apply the coating uniformly. Furthermore, by using the paint supply head of the present invention,
It is possible to manufacture products with excellent painting and pattern reproducibility without paint defects, and also has high surface hardness, designability,
In particular, it is possible to manufacture a decorative board excellent in light feeling, three-dimensional feeling, shadow feeling and deep feeling.
【図1】 この発明の実施の形態1に係る塗料供給ヘッ
ドを示す一部破断斜視図である。FIG. 1 is a partially broken perspective view showing a paint supply head according to Embodiment 1 of the present invention.
【図2】 図1の塗料供給ヘッドを示す一部破断正面図
である。FIG. 2 is a partially cutaway front view showing the paint supply head of FIG. 1;
【図3】 図1の塗料供給ヘッドを示す側面断面図であ
る。FIG. 3 is a side sectional view showing the paint supply head of FIG. 1;
【図4】 変形例に係る塗料供給ヘッドを示す側面断面
図である。FIG. 4 is a side sectional view showing a paint supply head according to a modification.
【図5】 変形例に係る塗料供給ヘッドを示す側面断面
図である。FIG. 5 is a side sectional view showing a paint supply head according to a modification.
【図6】 変形例に係る塗料供給ヘッドを示す側面断面
図である。FIG. 6 is a side sectional view showing a paint supply head according to a modification.
【図7】 フローコーターの全体構成を示す図である。FIG. 7 is a diagram showing an overall configuration of a flow coater.
1 タンク、2 塗料、3 ポンプ、4,16,17
導入管、5 塗料供給ヘッド、6,12 スリット、7
塗料カーテン、8,9 コンベア、10 塗料回収
桶、11 容器、13,28 斜面部、14 塗料溜ま
り部、15 供給管、18 供給孔、19,23,2
7,30 樋、20 開口部、21 外側面、22 液
面、24 鉛直部分、25 斜板、26 底板、29
内壁面、A被塗装物。1 tank, 2 paints, 3 pumps, 4, 16, 17
Inlet pipe, 5 paint supply head, 6, 12 slit, 7
Paint curtain, 8,9 conveyor, 10 paint collection tub, 11 containers, 13, 28 slope, 14 paint pool, 15 supply pipe, 18 supply hole, 19, 23, 2
7, 30 gutter, 20 opening, 21 outer surface, 22 liquid level, 24 vertical part, 25 swash plate, 26 bottom plate, 29
Inner wall surface, A coated object.
フロントページの続き (72)発明者 坂本 和夫 茨城県石岡市大字柏原6番1号 株式会社 建材技術研究所内 (72)発明者 河崎 英治 茨城県石岡市大字柏原6番1号 株式会社 建材技術研究所内 (72)発明者 加藤 丈尚 滋賀県愛知郡愛東町池の尻恵美須2番3号 株式会社エーアンドエーマテリアル滋賀 工場内 Fターム(参考) 4D075 AC14 CA02 CB14 CB15 DA06 DB14 DC02 EA41 EA43 EB22 EB35 EB38 EC01 4F041 BA07 BA43 CA04 4F100 AA00A AB01A AE01 AE01A AG00 AK01A AK01C AK01D AK25B AK51B AL01B AP00A AT00A BA02 BA03 BA04 BA07 CC00B DG01 DG10A DH02 EH46B EJ08B EJ54 EJ65D EJ91C GB07 HB00B JB14 JN01C Continuing from the front page (72) Inventor Kazuo Sakamoto 6-1 Kashiwara, Ishioka, Ibaraki Pref., Japan Construction Materials Research Institute Co., Ltd. (72) Inventor Eiji Kawasaki 6-1, Kashiwara, Ishioka, Ibaraki Pref. (72) Inventor Takehisa Kato 2-3-3 Emisuri, Ichinoshiri, Ito-cho, Aichi-gun, Aichi-gun, Shiga Prefecture F-term in the A & A Materials Shiga Plant (reference) 4D075 AC14 CA02 CB14 CB15 DA06 DB14 DC02 EA41 EA43 EB22 EB35 EB38 EC01 4F041 BA07 BA43 CA04 4F100 AA00A AB01A AE01 AE01A AG00 AK01A AK01C AK01D AK25B AK51B AL01B AP00A AT00A BA02 BA03 BA04 BA07 CC00B DG01 DG10A DH02 EH46B EJ08B EJ54 EJ65D EJ91C GB07 HB00B
Claims (11)
るための塗料供給ヘッドであって、 底部に形成された塗料流下用のスリットとこのスリット
の上部に連結された斜面部とにより塗料溜まり部が画成
された長箱状の容器と、 前記容器の内部に塗料を導入するための導入管と、 前記容器内に配設されると共に前記導入管に連結され且
つ前記導入管により導入された塗料を前記容器内に供給
するための開口部を有する供給手段と、 前記供給手段から供給された塗料を一旦受け入れると共
にその塗料を前記容器の塗料溜まり部に供給するための
開口部を有する混合分散手段とを備えたことを特徴とす
る塗料供給ヘッド。1. A paint supply head for forming a paint curtain by causing paint to flow down, and comprising a paint flow-down slit formed at a bottom portion and a slope portion connected to an upper portion of the slit, and a paint pool portion. A container having a long box shape defined therein, an introduction pipe for introducing paint into the inside of the container, and disposed in the container and connected to the introduction pipe and introduced by the introduction pipe. A supply unit having an opening for supplying paint into the container; and a mixing and dispersing unit having an opening for temporarily receiving the paint supplied from the supply unit and supplying the paint to the paint reservoir of the container. Means for supplying paint.
きで且つ前記混合分散手段の開口部の開口方向が上向き
であることを特徴とする請求項1に記載の塗料供給ヘッ
ド。2. The paint supply head according to claim 1, wherein the opening direction of the opening of the supply means is downward, and the opening direction of the opening of the mixing and dispersing means is upward.
混合分散手段の開口部の最下位置より下に位置すること
を特徴とする請求項2に記載の塗料供給ヘッド。3. The paint supply head according to claim 2, wherein the uppermost position of the opening of the supply means is located below the lowermost position of the opening of the mixing and dispersing means.
平行に配設された樋であることを特徴とする請求項1〜
3のいずれか一項に記載の塗料供給ヘッド。4. The apparatus according to claim 1, wherein said mixing and dispersing means is a gutter disposed substantially parallel to said slit.
4. The paint supply head according to any one of items 3 to 5.
に配設され且つ外周部に開口部が形成された管であるこ
とを特徴とする請求項1〜4のいずれか一項に記載の塗
料供給ヘッド。5. The supply device according to claim 1, wherein the supply unit is a tube disposed substantially parallel to the slit and having an opening formed in an outer peripheral portion. Paint supply head.
て形成された複数の孔からなることを特徴とする請求項
5に記載の塗料供給ヘッド。6. The paint supply head according to claim 5, wherein the opening of the tube comprises a plurality of holes formed along the length of the tube.
項に記載の塗料供給ヘッドを用いたフローコーターで塗
料を塗布し、これを硬化させて化粧層を形成することを
特徴とする化粧板の製造方法。7. A coating material is applied to the surface of the substrate by a flow coater using the coating material supply head according to claim 1, and the coating material is cured to form a decorative layer. Method of manufacturing decorative board.
板、樹脂板及びフィルムのうちのいずれかであることを
特徴とする請求項7に記載の化粧板の製造方法。8. The method according to claim 7, wherein the substrate is any one of a metal plate, an inorganic plate, a wooden plate, a paper plate, a resin plate, and a film.
ていることを特徴とする請求項7または8に記載の化粧
板の製造方法。9. The method for manufacturing a decorative board according to claim 7, wherein a base adjustment layer is provided on the substrate in advance.
リア層を前記化粧層上に形成することを特徴とする請求
項7〜9のいずれか一項に記載の化粧板の製造方法。10. The method for manufacturing a decorative board according to claim 7, further comprising forming a transparent or translucent top clear layer on the decorative layer.
液面を、混合分散手段の開口部から混合分散手段の最下
部までの範囲に維持することを特徴とする請求項7〜1
0のいずれか一項に記載の化粧板の製造方法。11. The liquid level of the paint in the paint supply head is maintained in a range from an opening of the mixing and dispersing means to a lowermost portion of the mixing and dispersing means.
The method for producing a decorative board according to any one of claims 0 to 10.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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JP2001127573A JP4612220B2 (en) | 2001-04-25 | 2001-04-25 | Decorative plate manufacturing method |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001127573A JP4612220B2 (en) | 2001-04-25 | 2001-04-25 | Decorative plate manufacturing method |
Publications (2)
Publication Number | Publication Date |
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JP2002320896A true JP2002320896A (en) | 2002-11-05 |
JP4612220B2 JP4612220B2 (en) | 2011-01-12 |
Family
ID=18976419
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JP2001127573A Expired - Lifetime JP4612220B2 (en) | 2001-04-25 | 2001-04-25 | Decorative plate manufacturing method |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2004359946A (en) * | 2003-05-14 | 2004-12-24 | Konica Minolta Medical & Graphic Inc | Inkjet ink set and recording method |
JP2006102659A (en) * | 2004-10-06 | 2006-04-20 | Sk Kaken Co Ltd | Apparatus and method for supplying coating material |
JP2012213857A (en) * | 2011-03-31 | 2012-11-08 | A & A Material Corp | Coated panel and method for manufacturing the same |
Citations (6)
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---|---|---|---|---|
JPS50151234A (en) * | 1974-05-28 | 1975-12-04 | ||
JPH01291934A (en) * | 1988-05-20 | 1989-11-24 | Kawai Musical Instr Mfg Co Ltd | Manufacturing method of decorative plywood |
JPH07116587A (en) * | 1993-10-29 | 1995-05-09 | Sekisui Chem Co Ltd | Production of plate for building |
JPH07136579A (en) * | 1993-11-24 | 1995-05-30 | Sekisui Chem Co Ltd | Production of architectural board |
JPH09294950A (en) * | 1996-05-07 | 1997-11-18 | Kuraray Co Ltd | Painting equipment |
JPH10109377A (en) * | 1996-10-08 | 1998-04-28 | Washi Chuetsu Board Kk | Decorative board with transfer printed part, coating roll and pressing roll for transfer for device for manufacturing the decorative board, and peeling of transfer film |
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2001
- 2001-04-25 JP JP2001127573A patent/JP4612220B2/en not_active Expired - Lifetime
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS50151234A (en) * | 1974-05-28 | 1975-12-04 | ||
JPH01291934A (en) * | 1988-05-20 | 1989-11-24 | Kawai Musical Instr Mfg Co Ltd | Manufacturing method of decorative plywood |
JPH07116587A (en) * | 1993-10-29 | 1995-05-09 | Sekisui Chem Co Ltd | Production of plate for building |
JPH07136579A (en) * | 1993-11-24 | 1995-05-30 | Sekisui Chem Co Ltd | Production of architectural board |
JPH09294950A (en) * | 1996-05-07 | 1997-11-18 | Kuraray Co Ltd | Painting equipment |
JPH10109377A (en) * | 1996-10-08 | 1998-04-28 | Washi Chuetsu Board Kk | Decorative board with transfer printed part, coating roll and pressing roll for transfer for device for manufacturing the decorative board, and peeling of transfer film |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2004359946A (en) * | 2003-05-14 | 2004-12-24 | Konica Minolta Medical & Graphic Inc | Inkjet ink set and recording method |
JP2006102659A (en) * | 2004-10-06 | 2006-04-20 | Sk Kaken Co Ltd | Apparatus and method for supplying coating material |
JP2012213857A (en) * | 2011-03-31 | 2012-11-08 | A & A Material Corp | Coated panel and method for manufacturing the same |
Also Published As
Publication number | Publication date |
---|---|
JP4612220B2 (en) | 2011-01-12 |
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